First thing you need is a piece of PVC piping, cut to the length of stick you want to make, minus a couple inches.
Now cut a strip of foam, giving a extra inch on eash side. I used a piece of carpet underlay, it give good cushioning and is very durable.
Now to prevent the stick from sliding around inside the padding use a strip of double sided tape.
About every 6″ or so wrap the stick, this makes warpping the entire stick easier and keeps it lined up right for that.
Using a small piece of foam, fill the ends, this gives a little padding for stabbing strikes.
Seal off the ends by taping over the tips in a “X” across the top.
Wrap the entire stick in tape. Duct tape is good, but other types should work as well. Hockey tape is not a good option as the glue bleeds through and after a while it gets pretty gross and yellow with threads peeling off.
Now all you need is someone to hit with it.